csm for railway infrastructure & rolling stock 1

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CSM for RailwayInfrastructure & Rolling

Stock

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CSM General presentation

CSM for Railway

Technological Offer

CSM Labs & Competences

Stages in our 50-year history

2013

Building up of Corporate Know-Howfor product & process development

Start selling of K-Hto new clients and

markets

Widening through RINA

network

China

Over 250 resources 200 patent 50 publications/year

RINA Group

Training

Classification

Certification

Testing

Consulting Engineering

Operation&Maintenance

Design

Materials

Engineering

Technology

Innovation

Inspection

Testing, Inspection & Certification

Innovation & Consulting

Piena scala - impianto pilota Business lines

Oil & Gas

Energy

Trasportation

Aerospace and Defence

Steel

CSM Profile

SOLUTION FORMETALS

NEW TECHNOLOGY&MATERIAL INNOVATION

ENVIRONMENTAL SOLUTION

Analysis of customer needs

Market benchmarking

Fit for purpose analysis and lab testing Experimental check at real scale

Complementary technical competences Positive experience from similar cases

Product/process suitable for the application/market New product/process with higher

performances/cheaper

CSM Approach

SOLUTION

VERIFICATION

IDEA

ASSESSMENT

CSM has both high level technical skills and state of the art laboratories which allows to assess product/process performances as well as to develop new solutions

CSM facilities

CSM uses Transmission Electron Microscopy (TEM) to characterize materials. Accelerating Voltage: 300

kVResolution 0.19 nm

NANO AND MICRO-SCALE

Combustion Station,

CSM Dalmine

PILOT PLANT-SCALEMEDIUM-SCALE

Testing and modelling

From nano to pilot plant scale

Failure hydraulic testMulti axial load testing machine

Fully instrumented test line & on shore burst test

Tube indentation facility

Full scale plant for H2S testing on vessel

Full scale tests

CSM New offer of Services

Technological support and assistanceNew operative practices, through process problem solving, structural integrity, failure analysis and on site support, technical support for patenting

New products developmentMetallurgical design of special steels, process parameters, development of high performance products (plates, coils, pipes, bends, etc), components (descalers, burners, etc) and welds

Product qualificationSmall and full-scale testing. Conventional and special lab testing (including toughness, high strain and stress corrosion testing)

Personnel training (steelmaking, casting, rolling, finishing, chemical and metallurgical labs)Classroom courses and on site coaching (theory, modeling, norms and practice). Personnel skilling for laboratory testing and analyses

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CSM New offer of Services

Environment & SustainabilityEmission abatement, Energy recovery from organic waste and process gases, Waste inertization and valorization, Emulsions and Water treatment

Testing (lab & full scale)More than 20 labs are available, check the web site for deep details: www.c-s-m.it

Expert on SiteMore than 80 experts on more than 20 disciplines (corrosion, process, metallurgy, welding, rolling, claims).

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http://www.c-s-m.it/

C-Mn High Steel GradeSour resistance C-SteelLined & CladCorrosion-Resistant AlloysPowders for ALMPowders for special coatingsMMC

Steelmaking & Casting & Rolling & Forging, Heat treatment & Surface conditioningOn-site problem solvingCommissioning & start upTraining

Carbon, Stainless, Electrical and Special Steels, Superalloys, Ceramics, Special coatingsFlat, Long Products and Tubes Automotive, Defense, Aerospace, Railway, Marine, White & Yellow Goods, Power Generation, Oil&GasApplication Engineering

Through process approachL2 / L3 Control SystemsTailor-made tools for qualityCustomer designed sensorsTechnological DB

Solid Waste ValorizationWater ManagementEmission ReductionEnergy Recovery

CSM Innovation Chain

FAR EASTBaosteelHandanJSWJISCOShigang

RUSSIAN FEDERATIONMMKOMKSant-Petersburg Electro-Technical CompanyUralmash

EUROPEAcroniArcelorMittalColakoglu MetalurjiErdemirLOI ItalimpiantiNLMK

Salzgitter AGSiemens VAITATA Steel EuropeThyssenKrupp StahlThyssenKrupp NirostaVesuviusVoestAlpine

ITALYABBABSAcciaieria ArvediAcciaieria di RubieraAcciaierie CalvisanoAcciaierie ValbrunaAcciaierie VeneteArvedi Tubi AcciaioBercoCogne AcciaiSpecialiDalmine Tenaris

GroupDanieli AutomationFeralpi GroupFerriere Nord PittiniFIAT Group FincantieriForge MonchieriForgiatura MaméGeberitElectroluxHenkelIndesitItalcementi

IvecoLucchiniMagnetto WheelsMarcegagliaMetinvestNLMK VeronaOriMartinPaul WurthPirelliSiemens VAISocietà delle FucineTechIntTenovaThyssenKrupp AST

LATIN AMERICAArcelorMittal (Brasil)

NORTH AMERICATernium HylsaTAMSA

MENAMobarakehJesco

AFRICAAfrican Industries (Nigeria)

Market & Main Clients

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CSM for Railway

Technological Offer– CSM for Railway Infrastructures

– CSM for Rolling Stock


CSM for Railway

Pearlitic & Bainitic rails

Head hardened rails

Wear resistance and rolling contact fatigue of rails

Rail welding, TW & FBW WPS

Rail Suppliers Qualification

Rail selection

RAILWAY TRACK

Failure analyses

Coatings and paints

Constructions for severe conditions

Special testing design & procedures

Total Cost of Ownerships evaluations

Training

RAILWAY INFRASTRUCTURES

Failure analyses

Special testing design

Innovative solutions for carriages

Design for high crash resistance

Full scale testing

Metallic spare parts suppliers qualifications

ROLLING STOCK

CSM experiences & solutions for Railway sector

For a Railway Operator and its main Suppliers and Contractors, CSM can provide support through the entire production line, from the rail development to the performance assessment of tracks. CSM own special facilities can be dedicated to develop project specific solutions, jointly with the suppliers, contractors and operators. Training is a central part of the services provided.

New Rail Development

Problem: Innovation in high performance rails, i.e. 350 grades or

higher, is daily carried out, even if their introduction seems rather slow.

Solutions offered are mainly generic, and hardly they are metallurgically designed from the real conditions of operation.

Approach: Multi scale, from steel microstructure up to rail in

operation Through process approach, from the production through

the use. A unique set of metallurgical models to design fit for

purpose rail microstructure and the production process with the supplier.

A complete set of labs for any kind of test, standard or designed for purpose.

Results: Roadmap for product development for specific railway

projects. Projects for technology transfer and research on rails and

joints. Support in rail choice and maintenance programmes Training for inspectors and operators.

CSM for Railway

Material & Component Qualification (also in severe conditions)

CSM for Railway

Problem: Rail is placed in operation as a welded component. Welding joints, if not accurately designed and qualified, is

the weakest point of failure.

Approach: Model aided joint microstructure design. Filler and procedure evaluation. Joint microstructure A unique set of metallurgical models

to design fit for purpose rail microstructure and the production process with the supplier.

A complete set of labs for any kind of test, standard or designed for purpose.

Results: Roadmap for product development for specific railway

projects. Projects for technology transfer and research on rails and

joints. Support in rail choice and maintenance programmes Training for inspectors and operators.

Design & Testing of Components & Structures (for severe conditions)

Problem: Train helps in shortening the distances and the time

spent in commuting safely. Nevertheless its passage in cities and towns can incur high levels of noise. Pre-painted barriers are available, but needing significant maintenance efforts.

Approach: Development of new steel sandwiches, based also on

stainless steel in order to drastically reduce maintenance.

Measurements of level of noise dumping are designed with full scale prototypes of barrier.

Environment attack resistance is also performed in different severe conditions.

Results: Total Cost of Ownership evaluations Design of barriers for specific client needs. Supply chain management and qualification On site monitoring of installations and follow up

CSM for Railway


Problem: Road or railway tunnels are subject to significant corrosion

factors, including water stagnation and flowing, aerosol, condensation, presence of NOx, SO2, dusts etc..

Fire resistance and internal lighting are important concerns during design and operation of tunnels.

Approach: Development and design of innovative sandwich panels. Multimaterial approach, carbon steel stainless steels etc.. Sample and full scale testing of corrosion resistance under

several point of view following the most recent international standards (i.e. EN10169-2, EN10169-3, ISO 6270-1, ASTM B117, EN13523-23 etc.)

Results: Total Cost of Ownership evaluations for specific projects Design of panels and structures for specific client needs. Supply chain management and qualification On site monitoring of installations and follow up

CSM for Railway

Material Selection (for severe conditions)

Problem: Selection of rails and joints suitable for service

in arctic environment

Approach: Fracture mechanics testing (CharpyV, DWTT,

KIC) at low temperature according to recognized Standards and Recommendations (GOST, EN, etc.).

Full scale rail joints testing on up to simulated -60̊ C.

Results: Nil Ductility Temperature determination,

Charpy-V and DWTT brittle-to-ductile transition temperature determination on laboratory (specimen) and full scale (rail) condition: rail and joints

DWTT lab test @ low temp

CSM for Railway


Problem: Thermal behaviour of certain infrastructures are of primary

importance in particular in territory subjected to a high seasonal spread.

Approach: Innovative coating characterized by very low solar reflectance index

have been individuated. A specific test with full scale demonstrators been tuned up to

establish the procedure to compare standard and innovative painted steel roofs.

Summer tests, July – September, carried out in different years.

Results: A new “cool” roof has been individuated Design of roofs and walls for specific client needs. Supply chain management and qualification On site monitoring of installations and follow up

CSM for Railway

Internal temperature evolution

Innovative roof thermal behaviour


Problem: There are environmental conditions where infrastructures are asked to

survive without any maintenance, because difficult and costly. Typical concrete solutions cannot guarantee to fulfill some

requirements, similarly as carbon steel proposals.

Approach: A prototype has been designed with a structural galvanised steel

frame made of both 50x50mm and 25x50mm 2mm thick cold profiles. Both floor and external wall are made of innovative stainless steel

sandwich panels with increased carrying capacity. Rigid soil with screw system to take care of not completely horizontal

surfaces. In operation from early ‘90 at CSM headquarters in Rome.

Results: Total cost of ownership evaluations. A real maintenance-less solution for very severe operating conditions. Simple design even for specific client needs. Supply chain management and qualification. On site monitoring of installations and follow up.

CSM for Railway

Full stainless steel office at CSM


Problem: Site construction, due to its temporary status, needs

certain infrastructures for staff, employees and operations.

After a disaster, for example an earthquake, cheap and quick to install houses and offices must be made available.

Approach: Easy to install, size tailored, weight limited. House focus Office focus Full scale demonstrators in service

Results: Several moveable houses and offices designed and

tested. TIR moveable solutions. Supply chain management and qualification. On site support.

CSM for Railway

Failure Analyses on components and structures

Problem: Components and structures of the railway infrastructure or

the rolling stock can be subjected to failure or present a performance lower than requested. The correct and unambiguous identification of the root cause is essential for identifying the proper countermeasures, towards the suppliers, the contractors, or for modifying the operational practices.

Approach: Verification of the requirements set in the purchase

specifications, the applied national or internationals standards, with identification of the tests and analyses to be performed.

Sample preparation, test execution with registration of all the parameters, analyses of the results of the tests and examinations of the microstructures.

Preparation of a detailed report for the client and discussion.

Results: Identification of the root cause of a failure or the lack of

performance Suggestion of modified prescription, tests or qualification

campaigns.

CSM for Railway

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CSM for Railway

Technological Offer

CSM Labs & Competences– Coatings & Surface Treatments

– Corrosion

– Welding

– High Performance Computing

– Special facilities (Lab and Full Scale Testing)

The main Tribometer characteristics are:

• Test Load: max 5000 N• Shaft angular speeds with speed

continuous control• 100-500 rpm (both directions)• 100-1200 rpm (both directions)

Railtrack Operation: Special Testing Design

CSM Services for Railway


Coatings & Surface Treatments

Surface Treatments Cleaning, Degreasing Surface conversion Mechanical finishing

Metallic & Ceramic Coatings

Hot dip coatings (Zn, Al, alloys)

Electrolytic coatings Thermal spray coatings Vapour deposition coatings

(PVD)

Organic Coatings Painting Fusion and film laminating

coating

Polymeric Materials Adhesives and sealants Metal-plastic composites Rubber & plastics

Hot Dip Technology

Physical Vapour Deposition (PVD)

Thermal SprayThick (0.5mm min) inner metallic protection up to 6m

Polymeric materialsAdhesive bonding


Coatings & Surface Treatments

CSM experience for Railway contractors

Assessment of infrastructures coatings / paints: External paints for steel structures New coated steels Stainless steel use

Basic coating characterizations (microstructure, thickness, hardness, …).

Evaluation of the coating resistance to deformations

Evaluation of the coating resistance to environments simulating actual applications

Mechanical testingFull Scale Environment Resistance Test

Flexural Test


High Performance Computing

Main fields of application are: Rolling Forging Hot forming processes Continuous casting process In service performances of components working

in severe thermo mechanical conditions Fluid Dynamics Casting

In almost all these fields microstructure solid phases evolution is taken into account by means of in house developed softwares.

Deep knowledge of related industrial processes


High Performance Computing

Framework Field Software

Process design

Hot/Cold Forming

ABAQUS

LS-DYNA

MSC-MARC

Welding SYSWELD

Casting PROCAST

Fluid Dynamic analysis FLUENT

Product design

Stress/Fatigue/Thermal/Shock analysis

MSC-MARC

MSC-NASTRAN

ABAQUS

OPTISTRUCT

BallisticLS-DYNA

ABAQUS

Crash analysisABAQUS

LS-DYNA


Lab & Full Scale Testing Facilities

Since 70’s CSM has been deeply involved in industrial research projects aimed at the experimental assessment of the structural integrity performances of materials and components for the oil and gas industry.

Essential tools for carrying such investigation are the CSM laboratories where both small scale (mechanical, corrosion and stress corrosion) and full scale testing is executed.

In particular the CSM’s Full Scale Testing Laboratory (FST Lab) is equipped with ad hoc design facilities for testing on a full scale base plates, pipes, welded joints, tubular connections, etc. reproducing the most severe in field service conditions (high pressure, low temperature, fatigue, combined loading, dynamic impact, aggressive environments, etc.).

Laboratories are located in Roma and in Sardinia (Capoterra, Elmas, Perdasdefogu).


Lab & Full Scale Testing Facilities – Mechanical Testing Laboratory

Evaluation of the mechanical behaviour of metallic materials and components on both small and large scale by means of conventional and innovative testing dedicated laboratories. Tests can be carried out simulating service life environment (air, saline fogs, sea water, cathodic protection) in a temperature range from -196°C up to +1100°C).

Testing typologies: Facilities:

20 Servo hydraulic testing machines from 100 up to 2500 kN

53 Testing machines mono e multispecimens (325 specimens in parallel can be tested) for creep tests (temperature max 1300°C)

1 Servo mechanical testing machine for creep fatigue

1 Servo mechanical testing machine for creep ceramic

Multipurpose platform for testing on component

Special testing carried out by sized frames

Mechanical testing at low and high temperature (tension, compression, bending). Hardness survey.

Fracture mechanics (CharpyV, KIC, CTOD, J-int. measured by SENB and SENT specimen, Segment test).

Creep and creep-fatigue on metallic and ceramic materials.

Fatigue (constant and variable amplitude, HLC, LCF and TMF).

Multi Plastic Straining Cycling (reproducing plastic strain history of interest).

Multiaxial fatigue testing on large scale components (pipes, plates, rails, welded joints)


Lab & Full Scale Testing Facilities – Mechanical Testing Laboratory

Welded plate, fatigue, max

frequency 2 Hz, max load 1000 kN

Creep Testing LabMechanical Testing Lab


Lab & Full Scale Testing Facilities – Residual Stress Laboratory

The Laboratory is located in Roma, within the Central Full Scale Testing Laboratory.

Methods that are available for residual stress measurement are: Strain gauge methods (Hole drilling, Sachs, sectioning, etc.); X-Ray Diffraction System (XRD).

Stress X-3000 Hole drilling


Lab & Full Scale Testing Facilities – Stress Corrosion Testing Laboratory

Evaluation of the material corrosion behaviour by accelerated test campaigns in simulating operating conditions using dedicated laboratories :

Corrosion and electrochemical laboratory Stress corrosion laboratory. High Temperature High Pressure (300bar, 300°C) testing in autoclaves.

Uniform Corrosion and Stress Corrosion Resistance of stainless steels in industrial environments: inorganic acids, chlorides, heavy brines, sulphides, caustics.

CSM’s attendance of Corrosion Standardisation Committee: NACE, EFC, ISO, API

(CSM is qualified ACHILLES as a supplier for the Oil Industry of the North Sea)


Lab & Full Scale Testing Facilities: EN, ISO, ASTM tests


Lab & Full Scale Testing Facilities – Full Scale Testing Laboratory

Drop Weight Tear Test (DWTT) Device

Equipment main features: Max fall height : 4m. Max Impact energy available : 29,000 Joule. Test at low temperature cooling down the sample at

the required temperature

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